Method for making a polyester fabric

ABSTRACT

A method for making a polyester fabric includes: (a) providing a plurality of fibers made from a polyester polymer; (b) spinning the fibers to form pre-oriented yarns; (c) texturing the pre-oriented yarns using air textured yarn techniques; (d) warping a portion of the textured yarns so as to form warp yarns; (e) wefting the remainder of the textured yarns so as to form weft yarns; and (f) weaving the warp and weft yarns to form the polyester fabric.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a method for making a polyester fabric, more particularly to a method using air jet textured yarn techniques to form a polyester fabric having a wool-like structure.

2. Description of the Related Art

Natural fibers include silk, wool and cotton. Wool fibers have excellent properties, such as water-repellent, hygroscopicity and dirt-resistance, attributed to their fiber structure. However, wool production is relatively scarce and expensive.

Polyester fibers have advantages of easy washing, quick dry, heat-durability, thermosetting and cost effectiveness. However, they have a smooth surface and thus lack a wool-like structure. Therefore, there is a need to produce polyester fibers having a wool-like or a fluff-life structure.

SUMMARY OF THE INVENTION

Therefore, the object of the present invention is to provide a method for making a polyester fabric that can overcome the aforesaid drawback associated with the prior art.

According to the present invention, a method for making a polyester fabric having a wool-like structure comprises: (a) providing a plurality of fibers made from a polyester polymer; (b) spinning the fibers so as to form pre-oriented yarns; (c) texturing the pre-oriented yarns using air textured yarn techniques so as to form air jet textured yarns having a fluff-like structure; (d) warping a portion of the air jet textured yarns on a reel so as to form warp yarns; (e) wefting the remainder of the air jet textured yarns on another reel so as to form weft yarns; and (f) weaving the warp and weft yarns so as to form the polyester fabric.

BRIEF DESCRIPTION OF THE DRAWING

In the drawing which illustrates an embodiment of the invention,

FIG. 1 is a flowchart to illustrate consecutive steps of the preferred embodiment of a method for making a polyester fabric according to this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates the preferred embodiment of a method for making a polyester fabric according to this invention.

The method for making a polyester fabric having a wool-like structure or a fluff-like structure includes: (a) providing a plurality of fibers made from a polyester polymer, formation of the fibers being conducted using extrusion techniques; (b) spinning the fibers at a high speed ranging from 3000 to 5000 m/min so as to form pre-oriented yarns (POYs); (c) texturing the pre-oriented yarns using air textured yarn techniques so as to form air jet textured yarns (ATYs) having the wool-like structure or the fluff-like structure; (d) warping a portion of the air jet textured yarns on a reel (not shown) so as to form warp yarns; (e) wefting the remainder of the air jet textured yarns on another reel (not shown) so as to form weft yarns; and (f) weaving the warp and weft yarns so as to form the polyester fabric.

Preferably, the polyester polymer is blended with a colorant so as to form dyed polyester fibers in step (a).

Preferably, the polyester polymer is made from polyethylene terephthalate (PET).

It is noted that since the pre-oriented (i.e., stretched in a direction) PET yarn has a higher structural strength than that of a non-oriented PET yarn, the pre-oriented PET yarn can be subjected to further treatment, such as being textured using the air textured yarn techniques.

With the inclusion of texturing the pre-oriented yarns using air textured yarn techniques in the method of this invention, the PET fibers thus formed can have a wool-like structure.

With the invention thus explained, it is apparent that various modifications and variations can be made without departing from the spirit of the present invention. It is therefore intended that the invention be limited only as recited in the appended claims. 

1. A method for making a polyester fabric having a wool-like structure, comprising: (a) providing a plurality of fibers made from a polyester polymer; (b) spinning the fibers so as to form pre-oriented yarns; (c) texturing the pre-oriented yarns using air textured yarn techniques so as to form air jet textured yarns having a fluff-like structure; (d) warping a portion of the air jet textured yarns on a reel so as to form warp yarns; (e) wefting the remainder of the air jet textured yarns on another reel so as to form weft yarns; and (f) weaving the warp and weft yarns so as to form the polyester fabric. 